Apparatus for induction hardening

ABSTRACT

An apparatus for magnetic induction hardening of a workpiece includes a magnetic tool having a body portion formed of a generally non-magnetic material. The body portion has a surface configured to be positioned in close proximity to the workpiece being hardened. The apparatus further includes a magnetic arrangement coupled to the body portion at or adjacent the surface of the body portion and configured to provide regions of alternating polarity. A workpiece holder is configured to support the workpiece in close proximity to the surface of the magnetic tool. A drive arrangement for rotating the magnetic tool relative to the workpiece holder about an axis of rotation is provided to induce heating of the workpiece to achieve a temperature in the austenitic range of the workpiece resulting in hardening of the workpiece through a microstructural transformation.

BACKGROUND

The present invention relates to magnetic induction heating ofcomponents, and more specifically to an apparatus for use in magneticinduction hardening (e.g., case hardening or through hardening) ofcomponents.

Case hardening through induction heating is commonly performed usingcopper coils or inductors energized with alternating current from apower supply. The hardening depth achieved by the inductor is a functionof the AC frequency applied, as determined by the power supply and thetransformer. The surface area hardened is a function of the poweravailable from the power supply and the geometry of the inductor.

The geometry of the inductor must be carefully tailored to the partbeing hardened to prevent overheating of portions of the part. Thisspecific geometry of the inductor must also be carefully coordinatedwith a power supply of particular frequency range. The close design tiesbetween the inductor and the power supply yields an induction systemthat is largely dictated by, and therefore dedicated to, the particularpart being hardened. For different parts, different inductors withdifferent power supplies must be used, leading to an inflexible processresulting in a high cost of part-dedicated tooling. Electricityconsumption for these conventional induction heating systems is alsohigh, further increasing the cost of the process.

SUMMARY

In one embodiment, the invention provides an apparatus for magneticinduction hardening of a workpiece. The apparatus includes a magnetictool having a body portion formed of a generally non-magnetic material.The body portion has a surface configured to be positioned in closeproximity to the workpiece being hardened. The apparatus furtherincludes a magnetic arrangement coupled to the body portion at oradjacent the surface of the body portion and configured to provideregions of alternating polarity. A workpiece holder is configured tosupport the workpiece in close proximity to the surface of the magnetictool. A drive arrangement for rotating the magnetic tool relative to theworkpiece holder about an axis of rotation is provided to induce heatingof the workpiece to achieve a temperature in the austenitic range of theworkpiece resulting in hardening of the workpiece through amicrostructural transformation.

In one aspect of the invention, the magnetic arrangement defines anumber of magnetic poles (nP), the drive arrangement rotates the toolrelative to the workpiece holder at a speed (RPM), and a frequency of atleast 5 kHz is achieved according to the equation Hz=(nP*RPM)/60.

In another aspect of the invention, the apparatus further includes aquenching system operable to quench the heated workpiece while it issupported by the workpiece holder.

In yet another aspect of the invention, the workpiece holder supportsthe workpiece to prevent rotation of the workpiece about the axis ofrotation and to prevent translation of the workpiece in the workpieceholder along the axis or rotation, while accommodating for thermalexpansion of the workpiece in the workpiece holder.

In yet a further aspect of the invention, the magnetic arrangementincludes a plurality of permanent magnets coupled to the body portion ator adjacent the surface, and configured to provide the regions ofalternating polarity. The body portion can include a plurality ofpockets formed therein and spaced from the surface such that a wallportion of the body is defined between the surface and each of theplurality of pockets. Each of the plurality of magnets is positioned ina respective one of the plurality of pockets.

In another aspect of the invention, the magnetic arrangement includes amember that is magnetized to include a plurality of magnetic regions,the magnetic regions defining the regions of alternating polarity. Themember can take the form of a ring, and can be connected to the bodyportion to define the surface.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial perspective view of an apparatus for magneticinduction hardening of a workpiece embodying the present invention.

FIG. 2 is a cross-sectional view of the magnetic tool of FIG. 1.

FIG. 3 is an end view of the magnetic tool of FIG. 1.

FIG. 4 is an enlarged partial view of a portion of the magnetic tool ofFIG. 1 showing a pocket for housing a magnet.

FIG. 4 a is a schematic view showing an alternative pocket arrangementfor housing magnets.

FIG. 5 is a schematic view of an alternate magnet arrangement andcorresponding flux diagram from that shown in FIG. 3.

FIG. 6 is a schematic view of yet another alternate magnet arrangementand corresponding flux diagram.

FIG. 7 is a cross-sectional view of another magnetic tool that can beused with the apparatus for magnetic induction hardening shown in FIG.1.

FIG. 8 is an end view of the magnetic tool of FIG. 7.

FIG. 9 is a cross-sectional view of yet another magnetic tool that canbe used with the apparatus for magnetic induction hardening shown inFIG. 1.

FIG. 10 is an end view of the magnetic tool of FIG. 9.

FIG. 11 is a partial section view of FIG. 1 showing the quenching systemembodying the invention.

FIG. 12 is a partial section similar to FIG. 11 showing an alternatequenching system embodying the invention.

FIG. 13 is a section view of a magnetic tool having an integralquenching system according to another embodiment of the invention.

FIG. 14 is a section view of yet another magnetic tool having anintegral quenching system according to another embodiment of theinvention.

FIG. 15 is an enlarged perspective view of the workpiece holder of FIG.1.

FIG. 16 is section view of the workpiece holder of FIG. 15.

FIG. 17 is a perspective view of an alternative collet pad for use withthe workpiece holder of FIG. 15.

FIG. 18 is a schematic view of a magnet arrangement to accommodate forworkpiece expansion.

FIG. 19 is a schematic view of another magnet arrangement to accommodatefor workpiece expansion.

FIG. 20 is a schematic view of yet another magnet arrangement toaccommodate for workpiece expansion.

FIG. 21 is a schematic view of a further embodiment of a magnetic toolfor through hardening.

FIG. 22 is a schematic view similar to FIG. 21, but shows heat treatingtwo surfaces of a workpiece without through hardening.

FIGS. 23 a and 23 b are schematic views showing hardening of disparatesections of a workpiece surface.

FIGS. 24 a and 24 b are schematic views showing the effect of magnetlength on the length of the case produces on a workpiece surface.

FIG. 25 is a schematic view showing the expected effect of magnet widthon case depth.

FIGS. 26 a, 26 b, and 26 c are schematic views showing the expectedeffect of shaped magnets on the shape of the case produced.

FIGS. 27 a and 27 b are schematic views showing potential systems forcooling the magnets.

FIG. 28 is a schematic view showing the use of flux concentrators withthe magnet.

FIG. 29 is a partial cross-sectional view showing an eddy currentconduit being used with a magnetic tool.

FIG. 30 is a partial cross-sectional view of yet another magnetic toolembodying the invention, and in which the magnetic arrangement takes theform of magnetized member.

FIG. 31 is an end view of the magnetic tool of FIG. 30.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways.

FIG. 1 illustrates a magnetic induction hardening apparatus 10 accordingto the present invention. The illustrated apparatus includes a magnetictool 14 and a workpiece holder 18 configured to support a workpiece 22to be induction hardened. In the illustrated embodiment, the workpiece22 is an annular ring such as that which would be used as a raceway fora bearing, however, the invention is applicable and adaptable forhardening workpieces of varying geometries.

A drive arrangement in the form of a rotary drive unit 26 is providedfor rotating the magnetic tool 14 relative to the workpiece holder 18(and therefore the workpiece 22) about an axis of rotation 30 to induceheating of the workpiece 22 to achieve a temperature in the austeniticrange of the workpiece 22 resulting in hardening of the workpiece 22through a microstructural transformation, as is understood by thoseskilled in the art of heat treating and hardening. While the drive unit26 is illustrated as including a spindle 34 operable to support themagnetic tool 14 for rotation, in other embodiments, the drive unit 26could be operable to rotate the workpiece holder 18 or the workpieceitself 22 while the magnetic tool 14 remains stationary. In yet anotherembodiment, two drive units 26 could be provided, one to rotate themagnetic tool 14 and the other to rotate the workpiece holder 18 and theworkpiece 22.

The illustrated apparatus 10 further includes a quenching system 38operable to quench the heated workpiece 22 while it is supported by theworkpiece holder 18. Integrating the quenching system 38 with theinduction hardening apparatus 10 simplifies and economizes the inductionhardening process. The illustrated quenching system 38 includes a quenchcollar 42 surrounding the workpiece 22 for showering the workpiece witha quenching medium (e.g., water or other quenching fluids) to transformthe austenite into martensite. The apparatus can be enclosed in ahousing (not shown) to contain and collect the quenching medium and toprotect the operator from the heat generated during the inductionhardening process. As will be described further below, the illustratedquench collar 42 is only one possible type of quenching system 38 thatcan be integrated with the apparatus 10. In yet other embodiments, thequenching function need not be integrated into the apparatus 10, but canbe performed at a separate quench station remote from the apparatus 10.In such case, the heated workpiece 22 would be removed from theworkpiece holder 18 and transported to the remote quench station forquenching.

FIGS. 2-4 illustrate the magnetic tool 14 in greater detail. Theillustrated magnetic tool 14 includes a mounting portion 50 in the formof a drive shaft, and a body portion 54 coupled to the mounting portion50. The mounting portion 50 can be releasably secured to the spindle 34,which is coupled to the drive unit 26 for rotation therewith (see FIG.1). The mounting portion 50 and the body portion 54 are each formed of agenerally non-magnetic material or a material deemed to have a lowrelative permeability, such as aluminum or austenitic stainless steel.The body portion 54 defines a surface 58 configured to be positioned inclose proximity to the workpiece 22. As best illustrated in FIGS. 1 and2, the illustrated body surface 58 is a radially outwardly-facingcircumferential surface that is tapered to correspond to the taperpresent on the inner surface of the annular workpiece 22. As shown inFIG. 2, an air gap G is defined between the surface 58 and the innersurface of the workpiece 22 that is being hardened (as supported by theworkpiece holder 18). In the illustrated embodiment, the air gap G isless than about 0.07 inches, can be between about 0.02 inches and about0.06 inches, and is shown as being about 0.02 inches. Of course, withworkpieces of differing geometries, the geometry of the surface 58 andthe size of the air gap G can be adjusted accordingly to achieve thedesired hardening results. These capabilities will be discussed infurther detail below.

The magnetic tool 14 includes a magnetic arrangement that, in thisembodiment, takes the form of a plurality of permanent magnets 62coupled to the body portion 54 at or adjacent the surface 58. In theembodiment illustrated in FIGS. 1-4, the plurality of permanent magnets62 are housed in respective pockets 66 defined or formed in the bodyportion 54 to be spaced from the surface 58 such that a thin wallportion 70 of the body portion 54 is defined between the surface 58 andeach of the plurality of pockets 66. As such, the magnets 62 are coupledto the body portion 54 via their placement in the pockets 66 at alocation adjacent the surface 58. The wall portion 70 separating thepockets 66 from the surface 58 provides a thermal barrier between themagnets 62 and the heated workpiece 22 so that the temperature of themagnets 62 is less likely to reach the Curie temperature of the magnets62, or the temperature at which the magnets 62 lose their magneticcharacteristics (i.e., become paramagnetic). The wall portion 70 can beless than 0.05 inches thick, and in the illustrated embodiment is about0.02 inches thick. In manufacturing the body portion 54 of the magnetictool 14 to achieve the desired thin wall portion 70, the pockets 66 canbe formed prior to the machining or turning process used to form thefinished surface 58.

The magnets 62 are inserted into the pockets 66 with a tight fit suchthat the magnets 62 will not substantially move around within thepockets 66. If the magnets 62 were allowed to move around substantiallywithin the pockets 66, the balance of the magnetic tool 14 could beadversely affected. Apertures 74 (see FIGS. 1 and 2) are formed tocommunicate between the pockets 66 and the environment. When the magnets62 are inserted into the pockets 66, air is allowed to escape throughthe apertures 74 as the tight-fitting magnets 62 slide into the pockets66. A cover 78 is coupled to the body portion 54 with fasteners 82 oncethe magnets 62 have been positioned in the pockets 66 to secure themagnets 62 therein. Should the magnets 62 become damaged or degrade fromnormal usage, the cover 78 can be removed to facilitate replacement ofthe magnets 62.

In the illustrated embodiments, the cross-section of the magnets 62 aswell as the pockets 66 is substantially square in shape, but othercross-sectional shapes (e.g., circular, trapezoidal—see FIG. 4 a, etc.)could be substituted. The pockets 66, and therefore the inserted magnets62, have a longitudinal axis 86 (see FIG. 2) that extends generallyparallel to the surface 58. As best represented in FIG. 3, the poles ofthe magnets 62 (e.g., North—N and South—S poles) are on two opposingelongated faces of the magnets 62 such that their N-S axis extendsradially when positioned in the pockets 66. In other words, either aNorth or South pole faces radially outwardly toward the surface 58. Themagnets 62 are inserted into the pockets 66 such that each magnet 62alternates in polarity from the adjacent magnets 62 around thecircumferential periphery of the body portion 54. Thus, the magnets 62are oriented and positioned in the pockets 66 to provide regions ofalternating polarity, or such that an alternating pole/polarityarrangement of N-S-N-S-N-S, etc. is achieved adjacent the surface 58.The illustrated magnetic tool 14 includes thirty-two magnets 62,although as will be discussed below, the number of magnets 62 can bevaried as desired. In any of the illustrated magnet arrangements, themagnets 62 should be arranged closely enough together to provide acontinuous magnetic field to interact with the workpiece 22 beinghardened.

The magnets 62 are preferably rare earth permanent magnets capable ofdelivering a continuous flux density of greater than 1 Tesla. Theillustrated embodiment uses neodymium-iron-boron (NdFeB) magnets ofabout 1.2 T and a Curie temperature of about 540 degrees Fahrenheit,however, other suitable rare earth magnets can also be used. In analternative embodiment, ceramic magnets can be alternatingly positionedbetween every two NdFeB magnets. The orientation of the NdFeB magnetswould be constant. The ceramic magnets can be electrically activated tocreate fields opposite in polarity to the NdFeB magnets. In yet otherembodiments, such as that described below in conjunction with FIGS. 30and 31, the magnetic arrangement need not be comprised of a plurality ofindividual permanent magnets, but instead can take the form of a memberthat is magnetized to provide regions of alternating polarity.

FIGS. 5 and 6 illustrate alternative magnet arrangements that can beused with the magnetic tool 14. In FIG. 5, the pole axis of each magnet62, when positioned in the pockets 66, would extend circumferentially sothat the magnets 62 are arranged as follows S-N|N-S|S-N|N-S|S-N|N-S,etc. to provide the regions of alternating polarity adjacent each magnet62. By orienting the poles to face each other in the array as shown, itis believed that the adjacent repelling poles would direct more of themagnetic field radially outwardly toward the workpiece 22. FIG. 5illustrates the flux pattern generated by such an arrangement.

FIG. 6 illustrates an in-line arrangement. The pole axis of each magnet62, when positioned in the pockets 66, would again extendcircumferentially, but the magnets 62 are arranged as followsN-S|N-S|N-S|S-N|S-N|S-N|N-S|N-S|N-S|, etc. In this arrangement, themiddle grouping of 3 adjacent magnets is oriented in the same direction,S-N|S-N|S-N|, while the groupings of 3 adjacent magnets on either sideof the middle grouping is oriented as N-S|N-S|N-S|. With thisarrangement, each grouping of three adjacent magnets 62 defines a regionof an alternating polarity from the adjacent groupings of magnets 62.With the eighteen magnet array shown, there would be six poles. FIG. 6illustrates the resulting flux pattern.

FIG. 4 a illustrates an alternative embodiment of magnet pockets 90 thatcan be used on the magnetic tool 14′. Each of the plurality of magnets62′ is positioned in a respective pocket 90 such that a surface of eachof the plurality of magnets 62′ is exposed to at least partially definethe surface 58′ of the body portion 54′. There is no thin wall portionseparating the magnets 62′ from the surface 58′. As shown in FIG. 4 a,the pockets 90 and magnets 62′ are of a trapezoidal or dovetailconfiguration such that the magnets 62′ can be inserted axially into thepockets 90, yet are retained radially within the pockets 90 due to thegeometry of the pockets 90 and the magnets 62′.

The required speed or rotational rate (RPM) at which the magnetic tool14 (and therefore the magnets 62) are rotated relative to the workpiece22 is a function of the number of magnetic poles formed based on theconfiguration of the magnets 62. The formula equating the frequency(Hz), the number of poles (nP), and the rotational rate (RPM) is setforth as Hz=(nP*RPM)/60. The factor of 60 is to convert the RPM torevolutions per second (RPS), producing a frequency similar to that of acurrent from a power supply. The frequency is directly proportional tothe number of poles and the rotational rate. Therefore, if therotational rate of the magnetic tool 14 is reduced, the same frequencycan be achieved by increasing the number of poles. It has been foundthat a frequency of at least 5 kHz is needed to achieve heating of theworkpiece to the austenitic temperature range needed to achieve themicrostructural transformation that results in hardening. Thus asufficient number of poles coupled with a sufficient rate of rotationcan be selected. A range from 5 kHz to 21 kHz can be used for inductionhardening depending on the particular workpiece being hardened and thedesired hardening results.

In addition to varying the number of poles and the rotational rate ofthe magnetic tool 14, other variables can affect the heating, andtherefore the hardening capabilities of the magnetic tool 14. Onevariable that can be adjusted as desired is the time it takes for themagnetic tool 14 to achieve the desired RPM, which can be referred to asthe “ramp time.” The horsepower (torque) of the drive unit 26 determinesthe minimum ramp time achievable. Another variable that can be adjustedas desired is the time the magnetic tool 14 remains at the desired RPM,which can be referred to as the “soak time.” The air gap G is yetanother variable that can be adjusted as desired. The size of the airgap G impacts the torque requirements of the drive unit 26, as smallerair gaps G require greater torque to overcome the attraction between themagnetic tool 14 and the workpiece 22. The size of the air gap G alsoimpacts the heating time (i.e., ramp time and soak time) to achieve adesired hardness characteristic (e.g., case depth). All of thesevariables can be adjusted individually and in conjunction with eachother as desired to achieve the desired hardening characteristics (e.g.,case depth).

Depending upon the construction of the magnetic tool 14 and therotational speeds required, a dynamic balancing system may beincorporated to balance the tooling. Whether a balancing system isutilized or not, a concentricity of about 0.004 inches or smallerbetween the mounting shaft 50 and the magnets 62 should be maintained.This will help provide proper and consistent heating of the workpiece 22by minimizing the variation in the air gap G during rotation of themagnetic tool 14, thereby helping to achieve the desired hardeningresults.

FIGS. 7 and 8 illustrate another magnetic tool 94 that could be usedwith the apparatus 10. Like the magnetic tool 14, the tool 94 includes amounting portion 98 in the form of a drive shaft, and a body portion 102coupled to the mounting portion 98. The mounting portion 98 can bereleasably secured to the spindle 34, which is coupled to the drive unit26 for rotation therewith (see FIG. 1). The mounting portion 98 and thebody portion 102 are each formed of a generally non-magnetic material ora material deemed to have a low relative permeability, such as aluminumor austenitic stainless steel. The body portion 102 defines a surface106 configured to be positioned in close proximity to a workpiece 22. Asbest illustrated in FIGS. 7 and 8, the illustrated body surface 106 isan axially-facing end surface of the body portion 102 that is configuredto correspond to an end surface of the workpiece 22. Of course, withworkpieces of differing geometries, the geometry of the surface 106 canbe adjusted accordingly to achieve the desired hardening results.

The magnetic tool 94 includes a magnetic arrangement that, in thisembodiment, takes the form of a plurality of permanent magnets 110coupled to the body portion 102 at or adjacent the surface 106. In theembodiment illustrated in FIGS. 7 and 8, the plurality of permanentmagnets 110 are housed in respective pockets 114 defined or formed inthe body portion 102 to be spaced from the surface 106 such that a thinwall portion 118 of the body portion 102 is defined between the surface106 and each of the plurality of pockets 114. As such, the magnets 110are coupled to the body portion 102 via their placement in the pockets114 at a location adjacent the surface 106. The wall portion 118separating the pockets 114 from the surface 106 provides a thermalbarrier between the magnets 110 and the heated workpiece 22 so that thetemperature of the magnets 110 is less likely to reach the Curietemperature of the magnets 110. The wall portion 118 can be less than0.05 inches thick, and in the illustrated embodiment is about 0.02inches thick.

The magnets 110 are inserted into the pockets 114 with a tight fit suchthat the magnets 110 will not substantially move around within thepockets 114. If the magnets 110 were allowed to move aroundsubstantially within the pockets 114, the balance of the magnetic tool94 could be adversely affected. As shown in FIGS. 7 and 8, the pockets114 are defined in a cover 122 that is coupled to and forms part of thebody portion 102 with fasteners 126 once the magnets 110 have beenpositioned in the pockets 114. In alternative embodiments, the pockets114 could be partially or completely formed in the body portion 102adjacent the cover 122. Should the magnets 110 become damaged or degradefrom normal usage, the cover 122 can be removed to facilitatereplacement of the magnets 110.

In the illustrated embodiments, the cross-section of the magnets 110 aswell as the pockets 114 is substantially square in shape, but othercross-sectional shapes (e.g., circular, trapezoidal—see FIG. 4 a, etc.)could be substituted. The pockets 114 and therefore the inserted magnets110 have a longitudinal axis 130 (see FIG. 8) that extends generallyparallel to the surface 106. As best represented in FIG. 8, the poles ofthe magnets 110 (e.g., North—N and South—S poles) are on two opposingelongated faces of the magnets 110 such that their N-S axis extendsaxially when positioned in the pockets 114. In other words, either aNorth or South pole faces axially toward the surface 106. The magnets110 are inserted into the pockets 114 such that each magnet 110alternates in polarity from the adjacent magnets 110 when viewedcircumferentially about the end of the body portion 102. Thus, themagnets 110 are oriented and positioned in the pockets 114 such that analternating pole/polarity arrangement of N-S-N-S-N-S, etc. is achievedadjacent the surface 106. The illustrated magnetic tool 94 includesfifty magnets 110, although the number of magnets 110 can be varied asdesired. The magnets 110 should be arranged closely enough together toprovide a continuous magnetic field to interact with the workpiece 22being hardened.

The magnetic tool 94 can be used for hardening an end surface of theworkpiece 22, or in other words, a surface of the workpiece that isgenerally perpendicular to the axis of rotation of the magnetic tool 94.The discussions above regarding the alternative magnet configurationsthat can be used, the relationship between frequency, poles, androtational speed, the variables such as ramp time, soak time, and airgap, and the concentricity between the mounting shaft and the magnetsapply equally to the magnetic tool 94 and to the other magnetic toolconfigurations discussed below.

FIGS. 9 and 10 illustrate another magnetic tool 134 that could be usedwith the apparatus 10. Like the magnetic tools 14 and 94, the tool 134includes a mounting portion 138 in the form of a drive shaft, and a bodyportion 142 coupled to the mounting portion 138. The mounting portion138 can be releasably secured to the spindle 34, which is coupled to thedrive unit 26 for rotation therewith (see FIG. 1). The mounting portion138 and the body portion 142 are each formed of a generally non-magneticmaterial or a material deemed to have a low relative permeability, suchas aluminum or austenitic stainless steel. The body portion 142 definesa surface 146 configured to be positioned in close proximity to aworkpiece 22. As best illustrated in FIGS. 9 and 10, the illustratedbody surface 146 is a radially inwardly-facing circumferential surfaceof the body portion 142 that is configured to correspond to a radiallyoutward surface of an annular (or cylindrical) workpiece 22. Of course,with workpieces of differing geometries, the geometry of the surface 146can be adjusted accordingly to achieve the desired hardening results.

The magnetic tool 134 includes a magnetic arrangement that, in thisembodiment, takes the form of a plurality of permanent magnets 150coupled to the body portion 142 at or adjacent the surface 146. In theembodiment illustrated in FIGS. 9 and 10, the plurality of permanentmagnets 150 are housed in respective pockets 154 defined or formed inthe body portion 142 to form part of the surface 146, and such that nothin wall portion is defined between the surface 146 and each of theplurality of pockets 154. As such, the magnets 150 are coupled to thebody portion 142 via their placement in the pockets 154 at a locationadjacent the surface 146. The pockets 154 are defined in part by a ringportion 158 of the body portion 142, and by a cover 162 coupled to andforming part of the body portion 142 with fasteners 166. Should themagnets 150 become damaged or degrade from normal usage, the cover 162can be removed to facilitate replacement of the magnets 150. In otherembodiments, the pockets 154 can be formed in different manners. Forexample, the pockets 154 could be formed in a similar fashion to thepockets 66 described above.

The magnets 150 are inserted into the pockets 154 with a tight fit suchthat the magnets 150 will not substantially move around within thepockets 154. If the magnets 150 were allowed to move aroundsubstantially within the pockets 154, the balance of the magnetic tool134 could be adversely affected.

In the illustrated embodiments, the cross-section of the magnets 150 aswell as the pockets 154 is substantially square in shape, but othercross-sectional shapes (e.g., circular, trapezoidal—see FIG. 4 a, etc.)could be substituted. The pockets 154 and therefore the inserted magnets150 have a longitudinal axis 170 (see FIG. 9) that extends generallyparallel to the surface 146. As best represented in FIG. 10, the polesof the magnets 150 (e.g., North—N and South—S poles) are on two opposingelongated faces of the magnets 150 such that their N-S axis extendsradially when positioned in the pockets 154. In other words, either aNorth or South pole faces radially toward the surface 146. The magnets150 are inserted into the pockets 154 such that each magnet 150alternates in polarity from the adjacent magnets 150 about thecircumference of surface 146 of the body portion 142. Thus, the magnets150 are oriented and positioned in the pockets 154 such that analternating pole/polarity arrangement of N-S-N-S-N-S, etc. is achievedadjacent the surface 146. The illustrated magnetic tool 134 includesforty magnets 150, although the number of magnets 150 can be varied asdesired. The magnets 150 should be arranged closely enough together toprovide a continuous magnetic field to interact with the workpiece 22being hardened. The magnetic tool 134 can be used for hardening aradially outwardly-facing surface of the annular workpiece 22.

FIG. 11 is a section view of the apparatus 10 shown with the magnetictool 14 moved axially away from (i.e., lifted upwardly as shown in FIG.11) its heating position relative to the workpiece holder 18 to allowthe workpiece 22 to be quenched by the quenching system 38. In otherwords, the magnetic tool 14 and the workpiece holder 18 are movablerelative to one another in a direction parallel to the axis of rotation30 between a first position for heating the workpiece 22 (see FIG. 2)and a second position for quenching the workpiece 22 (see FIG. 11). Thequench collar 42 surrounds the workpiece 22 as shown in FIG. 11 forshowering the workpiece 22 with the quenching medium 174 (see FIG. 11).As shown in FIGS. 1 and 11, the quench collar 42 includes a plurality ofapertures 178 formed in an angled wall 182 and that communicate with achamber 186 (see FIG. 11) that is supplied with the quenching medium174. Connectors 190 are fluidly connected to supply lines (not shown)that selectively supply the quenching medium 174 to the chamber 186.

As best shown in FIG. 11, the quenching medium 174 is directed throughthe apertures 178 toward the surface 58 of the magnetic tool 14 and isdeflected downwardly onto the workpiece 22, thereby showering theworkpiece 22 with the quenching medium 174. The second or quenchingposition of the magnetic tool 14 can be adjusted as desired to achievethe appropriate showering effect. The quench collar 42 is supported inposition above the workpiece holder 18 by a support structure 194. It isto be understood that different quench collar and support arrangementscan be substituted for those shown in the figures.

FIG. 12 illustrates an alternative quenching system 198 that can be usedwith the apparatus 10. In the quenching system 198, a conduit 202 iscoupled to and extends from within the workpiece holder 18′ such that adistal end 206 of the conduit 202 is positioned at least partiallywithin the workpiece 22 when the workpiece 22 is supported by theworkpiece holder 18′. As shown in FIG. 12, the magnetic tool 14″ ismodified slightly from the magnetic tool 14 to include an aperture orrecess 210 in the body portion 54″ sized and configured to receive atleast a portion of the distal end 206 of the conduit 202 when themagnetic tool 14″ is in the first position for heating the workpiece 22(i.e., when the surface 58″ is positioned in close proximity to theworkpiece 22). FIG. 12 illustrates the magnetic tool 14″ in the secondposition for quenching the workpiece 22. Quenching medium 174 flowsthrough the conduit 202 from a supply coupled to a connector 214, andexits the conduit 202 through apertures 218 formed in the distal end206. The apertures 218 extend circumferentially around the distal end206 to spray the quenching medium 174 a complete 360 degrees around thedistal end 206 and onto the workpiece 22. With the arrangement shown inFIG. 12, the quenching system 198 is integrated with the workpieceholder 18′.

FIG. 13 illustrates yet another alternative quenching system 222 whichis integrated with the magnetic tool 14′″. The mounting portion 50′″ andbody portion 54′″ of the magnetic tool 14′″ together define a conduit226 through which the quenching medium 174 can be supplied. The supplyof quenching medium 174 can be provided through the spindle (not shown).As shown in FIG. 13, the cover 78′″ is modified to include an extensionor protrusion 230 extending axially away from the mounting portion 50′″and that includes radially-oriented, circumferentially positionedapertures 234 communicating with the conduit 226 to permit the quenchingmedium 174 in the conduit 226 to be sprayed onto the workpiece 22 whenthe magnetic tool 14′″ is raised to the second, quenching position. Ifthe number and positioning of the apertures 234 are sufficient, thequenching can occur without rotating the magnetic tool 14′″, however, inother embodiments, the magnetic tool 14′″ can be slowly rotated duringthe quenching stage to better distribute the quenching medium 174.

FIG. 14 illustrates yet another alternative quenching system 238 that isintegrated with the magnetic tool 14″″. The mounting portion 50″″ andbody portion 54″″ of the magnetic tool 14″″ together define a conduit242 through which the quenching medium 174 can be supplied. Apertures246 extend through the body portion 54″″ from the conduit 242, radiallyoutwardly to the surface 58″″, and are positioned between adjacentmagnets 62″″. With this configuration, the magnetic tool 14″″ need notbe raised from the first, heating position in order to achievequenching. Instead, once the heating operation is completed, therotation of the magnetic tool 14″″ can be slowed or stopped and thequenching medium 174 can be supplied to the conduit 242 to quench theworkpiece 22 without raising the magnetic tool 14″″.

FIG. 15 illustrates the workpiece holder 18 and is shown with the quenchcollar 42 and the workpiece 22 removed for clarity. The workpiece holder18 includes a pneumatic or air chuck 250 designed to securely supportthe workpiece 22 with clamping forces sufficient to prevent bothrotation and translation of the workpiece 22 relative to the axis ofrotation 30. Due to the magnetic attraction between the magnetic tool 14and the workpiece 22, it is important that the workpiece 22 besufficiently clamped to prevent rotation and translation relative to theaxis of rotation 30. The air chuck 250 operates using air pressure toradially clamp the workpiece 22 via engagement with a plurality ofcollet pads 254. As shown in FIG. 15, six collet pads 254 are providedon the workpiece holder 18 to circumferentially surround and support theworkpiece 22. In other embodiments, the number of collet pads 254 canvary as desired.

Referring now to both FIGS. 15 and 16, the pads 254 are supported by apad support member 258 having a circumferential groove 262 (see FIG. 16)configured to receive a circumferential lip 264 (see FIG. 16) formed oneach pad 254. A fastening arrangement 268 is provided to further secureeach pad 254 to the pad support member 258. As shown in FIG. 16, the padsupport member 258 includes cam surfaces 272 that engage mating camsurfaces 276 of an upper support member 280. The upper support member280 is coupled to a lower support member 284 via fasteners 288 and via aplurality of compression springs 292 (only one is shown) to allow someslight relative vertical movement between the upper support member 280and the lower support member 284, even when the pneumatic clamping forceis applied to the air chuck 250 to bias the pads 254 in the radiallyinward clamping or securing direction to clamp the workpiece 22. Byproviding the compression springs 292, and by virtue of the cam surfaces272 and 276, the air chuck 250 is allowed to compensate for thermalexpansion of the workpiece 22 during the hardening process by allowingthe pads 254 to expand radially outwardly against the clamping biasduring the thermal growth of the workpiece 22. This helps minimize oreliminate any warping or distortion of the workpiece 22 during thehardening operation.

Still referring to FIGS. 15 and 16, the radial clamping by the pads 254substantially prevents rotation of the workpiece about the axis ofrotation 30. The pads 254 each include a projection 296 projectingupwardly from a generally horizontal surface 300 of the pad 254. Thelower surface of the workpiece 22 rests on each of the projections 296so that a point or small-area contact is achieved. The pads 254 eachalso include a generally vertical surface 304 against which the radiallyouter surface or diameter of the workpiece 22 abuts. This workpiecesupporting arrangement by each pad 254 is most clearly shown in FIG. 16.The pads 254 are made of para-magnetic materials, such as aluminum orstainless steel, and can be further configured such that the engagementbetween each pad 254 and the workpiece 22 occurs at locations on the pad254 that are electrically non-conductive. In the embodiment illustratedin FIGS. 15 and 16, each of the projections 296 and the verticalsurfaces 304 are coated with a non-conductive material, such as Teflon,ceramics, etc., such that the workpiece holder 18 electrically isolatesthe workpiece 22 from ground.

FIG. 17 illustrates an alternative embodiment of a collet pad 308 thatcan be used with the workpiece holder 18. Instead of the projections296, each pad includes a non-conductive insert or attachment 312 coupled(e.g., via a fastener 316) to the radially inner surface of the pad 308such that a portion of the insert 312 extends vertically above one ormore horizontal surfaces 320 defined by the pad 308. The bottom of theworkpiece 22 will rest on and be supported by the insert 312 above thehorizontal surfaces 320. While the illustrated insert 312 is shown asbeing a substantially diamond-shaped ceramic part, other non-conductivematerials and configurations can also be used.

Additionally, the pad 308 includes a plurality of further non-conductiveinserts or attachments 324 sized and configured to engage and supportthe outer surface or diameter of the workpiece 22. As shown in FIG. 17,the pad 308 includes a generally vertical surface 328 that terminates ata distal upper surface 332 of the pad 308. Three non-conductive inserts324 are coupled to the upper surface 332 so as to extend radiallyinwardly beyond the generally vertical surface 328. Substantially linecontact will occur between each insert 324 and the outer surface of theworkpiece 22, and the outer surface of the workpiece 22 will not contactthe generally vertical surface 328. In the embodiment illustrated inFIG. 17, the inserts 324 are ceramic cylinders. In differentembodiments, other non-conductive materials and configurations can beused. Together, the inserts 312 and 324 support the workpiece 22 suchthat the workpiece holder 18 electrically isolates the workpiece 22 fromground.

Referring once again to FIGS. 15 and 16, the workpiece holder 18 furtherincludes one or more clamps 336 operable to secure the workpiece 22 tohelp prevent translation of the workpiece 22 (e.g., upwardly) along theaxis of rotation 30 when the workpiece is supported by the pads 254,308. The illustrated clamps 336 are connected to the air chuck 250 alongan outer periphery and include clamp members 340 that extend radiallyinwardly toward the axis of rotation 30, over the upper end of the pads245, 308, and over the upper end surface of the workpiece 22 (see FIG.16). The clamp members 340 engage the workpiece 22 at a location on theclamp members 340 that is non-conductive, again so as to electricallyisolate the workpiece 22 from ground. In the illustrated embodiment, theclamps 336 (including the clamp members 340) are made of anon-conductive ceramic material. In other embodiments, para-magneticmaterial could be used and a non-conductive coating could be applied tothe end of the clamp members 340 that engages the workpiece 22. Theillustrated clamp members 340 each include two spaced-apart distal endprojections 346 that engage the workpiece 22, while the remainder ofeach clamp member 340 does not engage the workpiece, and does notinterfere with the magnetic tool 14. It is to be understood that otherconfigurations of the clamps 336 can also be used. Furthermore, morethan two clamps 336 can be used if desired.

The illustrated workpiece holder 18 is just one example of a workpieceholder that can be used with the apparatus 10. For example, aconventional three jaw chuck can be used to hold the workpiece 22.However, it has been found that the workpiece holder 18 described aboveis well-suited for preventing rotation and translation of the workpiece22, helps to prevent distortion of some workpieces 22 during heating,and is advantageous in its ability to electrically isolate the workpiece22 from ground.

As described above, the workpiece holder 18 can be designed toaccommodate thermal expansion or growth of the workpiece 22. Dependingupon the amount of thermal expansion a particular workpiece 22 mayundergo during heating for hardening, it may be desirable to also adjustthe air gap G between the surface 58 of the magnetic tool 14 and theadjacent surface of the workpiece 22 to achieve the desired hardeningcharacteristics, such as the case depth. FIG. 18 illustrates onepossible magnetic arrangement designed to accommodate thermal expansionof the workpiece 22 and that can be used in any of the magnetic toolsdiscussed above (shown in a magnetic tool similar to the magnetic tool134 of FIG. 9). Specifically, the magnets 62 can each be formed by astacked set (e.g., a pair) of magnets having a first or upper magnet 62a and a second or lower magnet 62 b radially offset from the firstmagnet 62 a. In other words, for an entire circular array of magnets 62,the array of upper magnets 62 a can be said to define a first magneticdiameter at a first axial location that is different from (e.g., smallerthan) a second magnetic diameter defined by the array of lower magnets62 b at a second axial location. In order to keep the gap Gsubstantially constant, the workpiece 22 can start in the upper positionrelative to the magnetic tool 14 (shown in solid lines in FIG. 18) sothat the workpiece 22 is adjacent the array of upper magnets 62 a. Asthe diameter of the workpiece 22 grows due to thermal expansion, themagnetic tool 14 can be moved (e.g., raised) relative to the workpiece22 so that the workpiece 22 (shown in phantom lines in FIG. 18) isadjacent the array of lower magnets 62 b. The radial offset between thearrays of magnets 62 a and 62 b is substantially the same as theexpected radial growth of the workpiece 22 so that consistent hardeningcan be achieved.

FIG. 19 illustrates an alternative magnetic arrangement similar inprinciple to the magnet arrangement shown in FIG. 18 for accommodatingthermal expansion of the workpiece 22. Instead of having stacked sets ofindividual magnets, the magnets 62 can be shaped or formed as shown tohave an upper portion that defines a first magnetic diameter at a firstaxial location that is different from (e.g., smaller than) a secondmagnetic diameter defined by the lower portion of the magnet 62 at asecond axial location.

FIG. 20 schematically illustrates another alternative magneticarrangement designed to accommodate thermal expansion of the workpiece22. Each of the magnets 62 is mounted so as to be movable in the radialdirection to vary a magnetic diameter defined by the array of magnets62. In the illustrated embodiment, each magnet 62 is curved or shapedand is coupled to a movable (e.g., pivoting) arm 350. The arm 350 pivotsabout pivot point 352 and engages a cam surface 354 (e.g., a conicalsurface) that can be adjusted in the direction of the axis 30 relativeto the arm 350 to cause the desired radial movement of the magnets 62 tomaintain or achieve the desired gap G as the workpiece 22 expands.

FIG. 21 schematically illustrates another arrangement of a magnetic tool358, which includes an inner ring or array of magnets M_(i) that definesa first, radially inner surface portion of the body of the magnetic tool358, and an outer ring or array of magnets M_(o) that defines a second,radially outer surface portion of the body of the magnetic tool 358. Theinner and outer rings of magnets M_(i) and M_(o) have alternating polesas described above. The inner ring of magnets M_(i) is in closeproximity to an inner surface W_(i) of the annularly-shaped workpiece 22while the outer ring of magnets M_(o) is in close proximity to the outersurface W_(o) of the workpiece 22. The inner and outer rings of magnetsM_(i) and M_(o) are rotated relative to the workpiece 22 such that eachring of magnets heats one half the annular width of the workpiece 22,such that the workpiece 22 will be through hardened (as indicated by thecomplete section line portion of the workpiece 22 in FIG. 21). Tocompensate for the fact that the workpiece outer surface W_(o) is longerthan the workpiece inner surface Wi, the inner and outer rings ofmagnets M_(i) and M_(o) can be rotated at different rates, can havedifferent numbers of poles, can be ramped up to the desired RPM atdifferent rates, and/or can be operated at the desired RPM for differentperiods of time. Additionally or alternatively, the air gaps G can bechanged.

FIG. 22 schematically shows the use of the magnetic tool 358 in anon-through hardening application. The magnets M_(i) and M_(o) are sized(i.e., have a magnetic field), or the magnetic tool 358 is operated suchthat a hardened case C is formed on the inner and outer workpiecesurfaces W_(i) and W_(o) without through hardening the workpiece 22.This will result in a more ductile interior of the workpiece 22.

The magnets of the magnetic tool can also be arranged to harden selected(and potentially separate) areas of the workpiece 22, to form a case Cof varying depth, or to form a case on a workpiece 22 having a morecomplex geometric shape (i.e., not generally cylindrical). FIG. 23 aschematically represents a magnetic tool 362 having a lower ring ofmagnets M_(L) positioned adjacent a lower portion of the workpiece 22and an upper ring of magnets M_(U) positioned adjacent an upper cornerof the workpiece 22. This configuration will produce a lower hardenedcase C_(L) and an upper hardened case C_(U) with an area between that isnot case hardened.

FIG. 23 b schematically illustrates another magnetic tool 366 havingupper and lower magnet rings M_(U) and M_(L) that are sized andconfigured to achieve a desired case hardening of the workpiece 22. Thelower case hardened area C_(L) is longer than the upper case hardenedarea C_(U). This is achieved by using a lower magnet ring M_(L) thathaving an effective axial length that is longer than the effective axiallength of the upper magnet ring M_(U). This can be achieved by usinglonger magnets on the lower magnet ring M_(L), or by stacking magnets toproduce a lower magnet ring M_(L) with a longer effective length.

FIG. 24 a schematically illustrates a magnetic tool 370 with a magnetring M having an axial length smaller than the axial length of theworkpiece 22. As shown, the magnet ring M is expected to produce ahardened case C that does not extend the full axial length of theworkpiece 22, leaving unhardened areas of the surface above and/or belowthe surface area that is case hardened.

FIG. 24 b shows the opposite situation from FIG. 24 a. The schematicallyillustrated magnetic tool 374 has a magnet ring M with an axial lengththat is larger than the axial length of the workpiece 22. As shown inFIG. 24 b, this arrangement is expected to produce a hardened case Cthat extends the full axial length of the workpiece 22.

FIG. 25 schematically illustrates a magnetic tool 378 in which the lowermagnet ring M_(L) has an annular width that is greater than the annularwidth of the upper magnet ring M_(U). Varying the annular width of themagnet ring can be accomplished using wider magnets for the wider magnetring, or by radially stacking magnets. As shown in FIG. 25, the widermagnet ring is expected to produce a thinner case depth C_(L) than thethinner magnet ring when the two rings are ramped up at the same rate,rotated at the same desired speed, and provided with the same soaktimes.

FIGS. 26 a-c show the expected results from using shaped magnets M inthe magnetic tools. In FIGS. 26 a, the magnet M is generally U-shaped,having an upper portion M_(U) and a lower portion M_(L) that are axiallyspaced from each other. The magnet upper portion M_(U) is axiallyshorter and radially shorter than the lower magnet portion M_(L). Asseen, this magnet configuration is expected to produce a lower caseC_(L) that is axially longer and radially deeper than the upper caseC_(U).

In FIG. 26 b, the magnet M has a surface S that is provided with adesired shape or profile. In a workpiece 22 with a flat surface facingthe magnet surface S, the shape of the surface S is expected to producea case C in which the transition T between the case and the core willgenerally correspond in shape or profile to the shape of the workpiecesurface S.

As shown in FIG. 26 c, shaped magnets M could also be used to caseharden shaped surfaces of a workpiece 22. In this instance, the magnetsurface S has a profile corresponding to the profile of the surface tobe hardened. This will maintain a constant air gap between the magnet Mand the workpiece surface, and should produce a hardened case C of asubstantially constant depth from the workpiece surface.

It is understood that the magnets used in the magnetic tools during theinduction hardening operation will be heated up. If the magnets exceedtheir Curie temperature, they will lose their magnetic properties andthe magnetic tool will no longer be effective. Therefore, in someapplications, it may be useful to provide a cooling system for themagnets in the magnetic tool. FIGS. 27 a and 27 b schematicallyillustrate two possible cooling systems that could be incorporated withany of the magnetic tools described above. In FIG. 27 a, the magnetictool 382 includes a plurality of magnets M (only one is shown) having asurface S facing the workpiece 22 to be hardened. A wall 386, which canbe integral with the body portion 54, defines an annular chamber 390 andis adjacent the ring of magnets M in heat transfer relation thereto(i.e., adjacent the surface opposite the surface S). The annular chamber390 contains a coolant 394 that can be supplied and circulated by asuitable system. The wall 386 is made from a material, such as aluminum,that will readily transfer heat. The wall 386 and the coolant 394 willabsorb the heat from the magnet M and conduct it away from the magnet Mto maintain the magnet M below the Curie temperature.

FIG. 27 b illustrates an alternative cooling system. In this system, themagnetic tool 398 includes a base 402, which can be integral with thebody portion 54, comprising a plurality of spacers 406 defining pockets410 that receive the magnets M. The base 402 includes a chamber 414having a main portion 414 a that passes behind the magnets M, and fingerportions 414 b that extend into the spacers 406. A coolant 418 iscontained within the chamber 414 and is supplied and circulated by asuitable system. With this cooling system, the magnets M have threesurfaces in heat transfer relationship with the base 402 and the coolant418 to draw heat away from the magnets M.

While the magnetic tools 382 and 398 are both shown to havecoolant-based cooling systems, the cooling system could alternatively oradditionally comprise a solid heat sink made from a material having ahigh heat transfer coefficient, which includes other means, such asfins, to radiate heat away from the magnets.

FIG. 28 illustrates yet another modification that can be applied to anyof the magnetic tools described above. Specifically, one or more fluxconcentrators 422 can be positioned about the magnets M in the magnetictool to achieve the desired magnetic field enhancements, therebyachieving the desired hardening effects. The flux concentrators 422 canbe made from various alloy steels, powdered metals, and the like.Additionally, coded magnets, i.e., magnets that are imprinted with afield that varies across the magnet's surface, can be used to vary oralter the magnetic field as desired.

FIG. 29 illustrates the use of an eddy current conduit 430 that can beused with one or more of the magnetic tools described above. As shown inFIG. 29, the magnetic tool 134 is used in conjunction with the eddycurrent conduit 430 to channel or conduct eddy current from the surface146, through the eddy current conduit 430, and to a surface 434 of aworkpiece 438. Due to the small diameter defined by the surface 434, itmay not be practical or possible to configure a magnetic tool to fitwithin the small diameter opening to be hardened. The number of polesthat can be positioned in the small space may be so limited that therotational rate required to achieve the needed frequency is higher thancan be achieved by the apparatus 10. In such cases, an eddy currentconduit, such as the conduit 430, can be designed for a particularapplication.

The illustrated eddy current conduit 430 is formed as a lamination ofsilicon steel. The eddy currents created by the rotating tool 134 arereceived by the conduit 430, which in turn induces the eddy currentsinto the surface 434 of the workpiece 438. The silicon steel laminationscan be machined or formed to accommodate the particular magnetic tooland the particular workpiece. The surface 442 of the conduit 430 isformed to match the contour of the surface 146 with the desired air gapG, while the surface 446 of the conduit 430 is formed to match thecontour of the surface 434 with the desired air gap G. The sameprinciples described above with respect FIGS. 18, 19, and 21-26 for theparticular configurations of the magnetic arrangement can be applied tothe formation of the surface 446 of the conduit 430.

The individual sheet steel laminations of the conduit 430 are capturedand held together by a clamping arrangement 450 that is centrallylocated within the conduit 430. Upper and lower clamp members 454 and458, respectively, are held together by one or more fasteners 462. Theconduit 430 is supported by a fixing support 466 that can be secured tothe workpiece holder 18 in any suitable manner. In the illustratedembodiment, the fixing support 466, the conduit 430, the workpieceholder 18 and the workpiece 438 are all stationary while the magnetictool 134 rotates. In other embodiments, the relative rotation betweenthe magnetic tool 134 and the workpiece 438 could be achieved byrotating the workpiece holder 18, the fixing support 466 and the conduit430.

The conduit 430 can be cooled by a cooling system if necessary. Coolantcan be circulated between the individual laminations to remove heat fromthe laminations, as would be understood by one of ordinary skill in theart.

FIGS. 30 and 31 illustrate yet another magnetic tool 470 embodying theinvention. The magnetic tool 470 is similar in many respects to themagnetic tool 134 described above except that the magnetic arrangementis different. More specifically, the magnetic arrangement of the tool470 is not comprised of a plurality of individual permanent magnets, butinstead takes the form of a member 474 that is magnetized to provideregions 478 of alternating polarity. The regions 478 take the place ofindividual magnets, but function in substantially the same manner as theindividual magnets. Namely, the regions 478 provide regions ofalternating polarity that enable the heating of the workpiece 22 viarotation of the member 474 relative to the workpiece 22.

As shown in FIGS. 30 and 31, the member 474 takes the form of a metalring that is formed or machined to the desired shape, depending on theparticular application. The ring can be formed from a powdered metal toallow for maximum shape selection. The same principles described abovewith respect FIGS. 18, 19, and 21-26 for the particular configurationsof the magnetic arrangement can be applied to the formation andconfiguration of the ring. Additionally, cooling systems like thosedescribed above with respect to FIGS. 27 a and 27 b can be used with themember 474.

Once the desired shape is achieved, the metal ring is magnetized toprovide the desired number and orientation of regions 478 to achieve thedesired number of poles. As shown in FIG. 31, the member 474 includesforty regions, each having its north-south axis oriented radially.Adjacent regions 478 have alternating poles facing in the radiallyinward direction to achieve a similar effect to the arrangementdescribed with respect to the magnetic tool 134. It is to be understoodthat other orientations of the regions 478 can be applied to the member474 to achieve similar effects to the particular magnet arrangements ofany of the different magnetic tools described in detail above. As usedherein and in the appended claims, the term “magnetic arrangement” isintended to contemplate both the use of a plurality of individualpermanent magnets as well as the use of a magnetized member like themember 474 or other magnetized members with regions that are configuredlike and achieve the same effects achieved by any of the individualmagnet configurations described above.

After it is magnetized, the member 474 can be coupled to the bodyportion 482 of the magnetic tool 470 using one or more fasteners 486 andwill define the surface 490 of the magnetic tool 470. It is to beunderstood that a plurality of different members 474, each having adifferent number of poles, a different configuration, etc. could be kepton hand for fast and easy interchangeability depending on the particularhardening application. Alternatively, the member 474 can be secured tothe body portion 482 via other suitable fastening methods. In onealternative embodiment, the member 474 could be positioned in an annularchannel defined in the body portion 482 so that the annular channelfunctions like the plurality of pockets into which individual magnetsare placed in the embodiments described above. Namely, the annularchannel could provide a thin wall portion that provides a thermalbarrier between the member and the surface. A cover could secure themember 474 in the channel in a similar manner to the covers describedabove.

Various features and advantages of the invention are set forth in thefollowing claims.

1. An apparatus for magnetic induction hardening of a workpiece, theapparatus comprising: a magnetic tool having a body portion formed of agenerally non-magnetic material, the body portion having a surfaceconfigured to be positioned in close proximity to the workpiece beinghardened; and a magnetic arrangement coupled to the body portion at oradjacent the surface of the body portion and configured to provideregions of alternating polarity; a workpiece holder configured tosupport the workpiece in close proximity to the surface of the magnetictool; and a drive arrangement for rotating the magnetic tool relative tothe workpiece holder about an axis of rotation to induce heating of theworkpiece to achieve a temperature in the austenitic range of theworkpiece resulting in hardening of the workpiece through amicrostructural transformation.
 2. The apparatus of claim 1, furthercomprising a quenching system operable to quench the heated workpiecewhile it is supported by the workpiece holder.
 3. The apparatus of claim2, wherein the magnetic tool and the workpiece holder are movablerelative to one another in a direction parallel to the axis of rotationbetween a first position for heating the workpiece, and a secondposition for quenching the workpiece.
 4. The apparatus of claim 2,wherein the quenching system includes a quench collar surrounding theworkpiece for showering the workpiece with a quenching medium.
 5. Theapparatus of claim 2, wherein the quenching system includes a conduitcoupled to the workpiece holder to be positioned at least partiallywithin the workpiece.
 6. The apparatus of claim 5, wherein the bodyportion of the magnetic tool includes a recess sized and configured toreceive at least a portion of the conduit when the surface of the bodyportion is positioned in close proximity to the workpiece.
 7. Theapparatus of claim 2, wherein the quenching system is integrated withthe magnetic tool.
 8. The apparatus of claim 7, wherein the body portionof the magnetic tool defines a conduit through which quenching mediumflows.
 9. The apparatus of claim 1, wherein the magnetic arrangementincludes a plurality of permanent magnets coupled to the body portion ator adjacent the surface and configured to provide the regions ofalternating polarity.
 10. The apparatus of claim 9, wherein the bodyportion includes a plurality of pockets formed therein and spaced fromthe surface such that a wall portion of the body portion is definedbetween the surface and each of the plurality of pockets, and whereineach of the plurality of magnets is positioned in a respective one ofthe plurality of pockets.
 11. The apparatus of claim 10, wherein thewall portion is less than 0.05 inches thick.
 12. The apparatus of claim11, wherein the wall portion is about 0.02 inches thick.
 13. Theapparatus of claim 9, wherein the body portion includes a plurality ofpockets formed therein, and wherein each of the plurality of magnets ispositioned in a respective one of the plurality of pockets such that asurface of each of the plurality of magnets is exposed to at leastpartially define the surface of the body portion.
 14. The apparatus ofclaim 1, wherein the surface of the body portion is a radiallyoutwardly-facing circumferential surface configured for inductionhardening an inner surface of an annular workpiece.
 15. The apparatus ofclaim 1, wherein the surface of the body portion is a radiallyinwardly-facing circumferential surface configured for inductionhardening an outer surface of an annular workpiece.
 16. The apparatus ofclaim 1, wherein the surface of the body portion is an axially-facingsurface configured for induction hardening an end surface of an annularworkpiece.
 17. The apparatus of claim 1, wherein the magneticarrangement is configured to accommodate thermal expansion of theworkpiece during heating.
 18. The apparatus of claim 17 wherein themagnetic arrangement defines a first magnetic diameter at a first axiallocation, and a second, different magnetic diameter at a second axiallocation.
 19. The apparatus of claim 17, wherein the magneticarrangement includes a plurality of permanent magnets coupled to thebody portion at or adjacent the surface and configured to provide theregions of alternating polarity, and wherein the plurality of magnetsare movable in the radial direction to vary a magnetic diameter definedby the magnets.
 20. The apparatus of claim 1, wherein the magnetic toolincludes a mounting portion coupled to the body portion, wherein themounting portion includes a mounting shaft sized and configured to bereceived in a spindle, and wherein the drive arrangement includes adrive unit operable to rotate the spindle.
 21. The apparatus of claim20, wherein the mounting shaft and the plurality of magnets has aconcentricity of about 0.004 inches or smaller.
 22. The apparatus ofclaim 1, wherein the body portion is made of a material having lowpermeability.
 23. The apparatus of claim 22, wherein the body portion ismade of one of aluminum and austenitic stainless steel.
 24. Theapparatus of claim 1, wherein the magnetic tool further includes atleast one flux concentrator.
 25. The apparatus of claim 1, wherein themagnetic arrangement includes a plurality of regions each having anorth-south axis, the magnetic arrangement being arranged such that anorth-south axis of each of the plurality of regions extends in at leastone of a generally radial direction and a generally axial direction. 26.The apparatus of claim 1, wherein the magnetic arrangement includes aplurality of regions each having a north-south axis, the magneticarrangement being arranged such that a north-south axis of each of theplurality of regions extends in a generally circumferential direction.27. The apparatus of claim 1, wherein the surface of the body includes afirst, radially inner surface portion configured to be in closeproximity to an inner surface of an annularly-shaped workpiece, and asecond, outer surface portion configured to be in close proximity to anouter surface of the annularly-shaped workpiece.
 28. The apparatus ofclaim 27, wherein the workpiece is through hardened.
 29. The apparatusof claim 27, wherein a hardened case is formed on the inner and outersurfaces of the annularly-shaped workpiece.
 30. The apparatus of claim1, wherein the workpiece holder supports the workpiece with a clampingforce sufficient to prevent rotation of the workpiece about the axis ofrotation and to prevent the workpiece from translating along the axis ofrotation.
 31. The apparatus of claim 30, wherein the workpiece holderincludes a plurality of pads operable to secure the workpiece to preventrotation of the workpiece about the axis of rotation.
 32. The apparatusof claim 31, wherein each of the pads includes a projection on which theworkpiece rests.
 33. The apparatus of claim 31, wherein engagementbetween each pad and the workpiece occurs at locations on the pad thatare electrically non-conductive.
 34. The apparatus of claim 33, whereinthe locations are coated with a non-conductive material.
 35. Theapparatus of claim 33, wherein the locations are defined bynon-conductive inserts coupled to the pad.
 36. The apparatus of claim31, wherein each of the pads is biased in a securing direction andthermal expansion of the workpiece is accommodated by the pads beingpermitted to move in opposition to the bias.
 37. The apparatus of claim30, wherein the workpiece holder includes a clamp operable to secure theworkpiece to prevent translation of the workpiece along the axis ofrotation.
 38. The apparatus of claim 37, wherein engagement between theclamp and the workpiece occurs at a location on the clamp that iselectrically non-conductive.
 39. The apparatus of claim 38, wherein thelocation is coated with a non-conductive material.
 40. The apparatus ofclaim 38, wherein the clamp is made of a non-conductive material. 41.The apparatus of claim 1, wherein the workpiece holder electricallyisolates the workpiece from ground.
 42. The apparatus of claim 1,wherein the workpiece holder supports the workpiece in a manner thataccommodates thermal expansion of the workpiece.
 43. The apparatus ofclaim 1, wherein the workpiece holder supports the workpiece at adistance spaced from the surface of the magnetic tool, the distancebeing less than about 0.07 inches.
 44. The apparatus of claim 42,wherein the distance is about 0.02 inches to about 0.06 inches.
 45. Theapparatus of claim 1, wherein the magnetic arrangement defines asufficient number of magnetic poles (nP) and the drive arrangementrotates the magnetic tool relative to the workpiece holder at asufficient speed (RPM) to achieve a frequency of at least 5 kHzaccording to the equation Hz=(nP*RPM)/60.
 46. The apparatus of claim 45,wherein the frequency is between 5 kHz and 21 kHz.
 47. The apparatus ofclaim 1, wherein the magnetic arrangement defines a surface profile of adesired shape corresponding to a desired case hardening profile for theworkpiece.
 48. The apparatus of claim 1, wherein the magneticarrangement defines a surface profile of a desired shape correspondingto a surface profile of the workpiece.
 49. The apparatus of claim 1,wherein the magnetic arrangement includes a member that is magnetized toinclude a plurality of magnetic regions, the magnetic regions definingthe regions of alternating polarity.
 50. The apparatus of claim 49,wherein the magnetized member is a ring connected to the body portion,the ring defining the surface.
 51. The apparatus of claim 1, furthercomprising an eddy current conduit positioned adjacent the surface andconfigured to conduct eddy current from the magnetic tool to a surfaceof the workpiece.
 52. The apparatus of claim 51, wherein the eddycurrent conduit includes a lamination of silicon steel. 53-69.(canceled)